MX2010010710A - Multi-directionally swept beam, roll former, and method. - Google Patents

Abstract

A high-strength beam includes first and second sections bent in opposite directions as part of a roll-forming process. A frame includes side frame members incorporating the double-bent beam and at least one energy management tube attached to the beam. In one form, the beam is tubular and has a cross-sectional dimension of greater than 25 mm and a material strength of at least about 60 KSI tensile strength. A roll form apparatus includes a roll former device and a sweep station in-line with the roll former device for sweeping the continuous beam in first and second opposing directions. Also, a method of roll-forming comprises steps of: roll-forming a sheet of material into a continuous beam and sweeping first and second sections of the beam in opposite directions.

Description

MULTIDIRECTIONAL SWEEPING BEAM, ROLLER FORMER, AND METHOD Field of the Invention The present invention relates to multidirectional sweeping beams and also a roll forming apparatus and methods for forming multidirectional sweeping beams and structural members, such as can be used as defense reinforcement beams, vehicle frames, and non-linear structural members. . The present invention also relates to beams and structural members made therefrom. The present invention is not limited to only reinforcing beams of fenders and / or vehicle frames, nor is it limited to apparatus and methods for forming / constructing only these components.

Background of the Invention Roller formation can be a particularly cost-effective way to produce elongated beams and structural members (channel and tubular), since roller formation is capable of mass production of high volumes, with relatively inexpensive tools and tools of longer duration (as compared to stamping dies, especially when the high-strength materials being formed will quickly wear stamping dies). However, the REF.:213984 Roll formation has limitations, such as a limited capacity to form non-linear products.

Various ways of forming sweeps and elongated structural members in the form of a curve are known. For example, see Sturrus Patent of E.U.A. No. 5,092,512, Sturrus Patent of E.U.A. No. 5,454,504, and Lyons Published Application of E.U.A. 2006/0277960 which describes ways of imparting sweeps on a continuous beam made of high strength material, where the beam has a strength and shape suitable for use as a defense reinforcement beam. However, these processes are limited to forming sweeping beams to form unidirectional concave shapes. These processes are not capable of forming a beam with alternating sweeps (forward and backward), where the alternative sweeps are in opposite directions away from a central line formed by a roller.

In particular, the difficulties of consistently swept beams and structural members in nonlinear shapes are increased to a greater extent as the size and bending moment of a structural beam increase, such as when the beam has a tubular cross section of greater than 50 mm x 50 mm, and / or when the sheet material has a high strength (for example, greater than around 414 MPA (60 KSI) of tensile strength up to 1517 MPa (220 KSI) of tensile strength) , and / or when bending The sweep is relatively sharp such as the definition of a radius of less than 1500 mm, and / or when the thickness of the blade is greater than 2 mm, especially for combinations of the above.

Brief Description of the Invention In one aspect of the present invention, a roll forming apparatus includes a roll former with rollers for forming a sheet of steel material in a structural beam defining a longitudinal line. The apparatus further includes a scanning station in line with the roll former, wherein the sweep station includes a swept forming device selectively for scanning the structural beam in a first direction away from the longitudinal line and in a second direction. opposite to the first direction away from the longitudinal line while continuously operating the roll former.

In another aspect of the present invention, a scanning station is provided for scanning sections of a beam outside a longitudinal line defined by the beam. The sweep station includes a main armature, and a sweep forming device that includes a sub-frame operatively supported on the main armature for movement to a first position to sweep a first section of the beam in a first direction away from the longitudinal line and for movement to a second position to sweep a second section of the beam in a second direction away from the longitudinal line, the second direction being on a side opposite to the first address.

In another aspect of the present invention, a roller forming method comprises steps of: forming by roll of a sheet of material in a continuous beam defining a longitudinal line; and during the roll forming step, which sweeps a first section of the continuous beam in a first direction away from the longitudinal line and which. sweeps a second section of the continuous beam away from the longitudinal line in a second direction different from the first direction.

In a more concrete aspect of the present invention, the method includes forming an armature incorporating the beam with first and second sections oppositely swept.

In a more specific aspect of the present invention, the beam forms a defense reinforcement beam and / or a vehicle reinforcement component.

In a more concrete aspect of the present invention, an energy absorbing defense mounting bracket is attached to the beam at one end of the beam.

In a more concrete aspect of the present invention, the beam is tubular and has a cross-sectional dimension in a direction of flexion that is at least about 25 mm. In addition, the material strength is preferably at least about 414 MPA (60 KSI) of tensile strength, to provide a high strength to weight ratio.

An object of the present invention is to provide a beam, either in channel or tubular form, made of steel sheet material (or having similar or greater tensile strength) and with a cross section of considerable size (such as 5.08 cm (2 inches) or more in a direction of bending), where the beam is swept back and forth in opposite directions of a central line formed by roller during the roll forming process.

An object of the present invention is to provide an apparatus and method capable of sweeping a beam of considerable material strength and cross-section beam strength in a forward and backward pattern including sections of bending in opposite directions of a line central in the form of a roller.

It is an object of the present invention to construct an armature using the beam components with swept back and forth as noted above.

An object of the present invention is to provide internal and / or external stabilizers in an apparatus that forms roller to allow the apparatus to make increasingly sharp sweeps on a beam while maintaining the dimensional accuracy and the consistency of the cross section of the beam.

These and other aspects, objects, and features of the present invention will be understood and appreciated by those skilled in the art during the study of the following specification, claims, and appended drawings.

Brief Description of the Figures FIG. 1 is a side view of a roll forming apparatus including a bi-rectional scanning station of the present invention.

FIGS. 2-3 are perspective views of one end of the roll forming apparatus including the bi-directional scanning station of FIG. 1, FIG. 3 that includes parts removed to better show the components here aba o.

FIGS. 4-5 are top and perspective views of the scanning station of FIG. 3 in an initial position where the continuous beam remains linear passing this through the sweep station.

FIGS. 6-7 are top and perspective views of the scanning station similar to FIGS. 2-3 in a first position where the continuous beam is swept in a first address "B" outside its central line formed by roller.

FIGS. 8-10 are two perspective views and a top view of the scanning station of FIG. 3 in a second position where the continuous beam is swept in a second direction "C" opposite the first direction and outside its central line formed by a roller.

FIG. 11 is a top view of a defense reinforcement beam (also called "beam segment") formed in two directions by the apparatus of FIG. 1 in such a way that the final sections of the beam are co-linear but a central section is compensated.

FIG. 12 is a perspective view of a vehicle frame incorporating bi-directionally bent beam components that together will be welded together with mounting brackets (such as for mounting defense reinforcement beams) to form a complete vehicle frame.

FIG. 13 is a schematic flow diagram showing a method / process for making a vehicle frame.

FIGS. 14-18 are side views, in upper cross section, in perspective, in exploded perspective, and in broken perspective of an internal mandrel, and FIG. 19 is a modified segment of what is shown in FIG. 17 FIGS. 20-28 are similar to FIGS. 2-10, but showing another version of the bidirectional scanning station.

FIGS. 29-30 are perspective views of the sweep and assembly sub-frame with FIG. 30 that has some components removed to better show other components inside.

Detailed description of the invention A roll forming apparatus 30 (FIG 1) is provided which includes a roller former 31 (also called a "roll forming device") for the formation of a continuous beam 33 along the line direction "A" ", and a scanning station 32 in line with the roller forming device 31 for sweeping (i.e., longitudinally curved) the continuous beam 33 in first and second opposed directions of a continuous beam center line (also called" bi-flexing "). -directional "or" bilateral sweeping "herein)" on the fly "during the continuous operation of the roller forming device 31. Also, a related method of roll forming comprising roll forming steps of a sheet is described. material in a continuous beam and sweeping of first and second sections of the beam in opposite directions of the center line. Notably, the apparatus that Roll form can form the beam to include any number of different sections of sweep, depending on the functional requirements of the application where the structural beam will be used, as discussed below. The roll forming apparatus that includes the sweeping station is robust and is therefore capable of forming a variety of metal materials having different strengths (such as materials of 275 MPa (40 KSI) of tensile strength or less, up to 1517 MPa (220 KSI) of tensile strength or more) and many different sizes including large beam sections in cross section (such as 40 mm x 150 mm, or 40 mm x 40 mm, or 80 mm x 120 mm ) and many different shapes of cross sections (such as "B," "D," "C" or other shapes in cross section). The illustrated continuous beam 33 is cut into beam segments 34 (also called "reinforcement beams" or "structural girders" or "defense girders") having a length and shape suitable for use as defense reinforcement beams.

An exemplary defense reinforcement beam 34 (FIG 11) is made of high strength material such as 414 MPA steel (60 KSI) of tensile strength with wall thickness of about 2 mm sheet thickness, and It has a tubular shape of cross section with depth of 80 mm and similar height (in a vehicle mounted position). The beam 34 can be used as a defense reinforcement beam, and it may include a hole 34 'such as to support a ball / trailer hitch. The illustrated beam has a cross section that defines a single tube, but it is contemplated that a beam may define multiple tubes (e.g., in the form of B) or an open channel (e.g., in the form of a C). The illustrated beam 34 is formed in the roll forming apparatus 30 to include multiple sections 35-40, with sections 36/37 bent in the scanning station in opposite directions and sections 38/39 bent in opposite directions as part of the scanning process simultaneous with and during the roll forming process. As illustrated, the beam 34 can be used as a defense reinforcing beam, with ends 35 and 40 including soda mounting brackets (not specifically shown) that are configured to attach to a vehicle. Many defense mounting supports are known in the art, such that a detailed discussion of them is not necessary.

Notably, the central section 37/38 defines a single plane with ends 35 and 40, but the center section 37/38 is bent to a misaligned position relative to the ends 35 and 40 as part of the roll forming and sweeping operation . The central section 37/38 can additionally be reformed in a secondary operation to the position of the central section 37/38 backwards as well as below the ends aligned 35 and 40 (with upper and lower surfaces maintained in a horizontal orientation, when in the mounted position of vehicle.) This allows the use of a simple cross beam (34) to support a hitch (and tow bar) (see hole 34 'to receive a ball hitch), still allows adequate height and forward position in the bow of the hitch relative to the armor of the vehicle. In addition, it allows all of the orthogonal walls of the beam (34) to be oriented optimally in horizontal and vertical positions to support the weight.

A variety of different structural and reinforcement components can be made using the concepts incorporated in the shape of the beam 34. For example, FIG. 12 illustrates a vehicle frame, where components 111, 121, 125-127 are welded together (or bolted) together to form a basic passenger vehicle frame (see FIG 12), which includes features for cleaning vehicle wheels and for provide optimal non-linear support for your engine and vehicle suspension components. Remarkably, the bilateral sweeping beam sections made by the present roller forming apparatus 30 can be used to form side frame members and cross beam members. Eof the illustrated beams incorporates strategically placed push-ups, at least two of the push-ups that are formed in opposite directions of a line central beam continuous. It is contemplated that a large number of additional structural armor members and components can be made, including armor for sports vehicles such as snowmobiles and all-terrain vehicles; armor for other vehicles such as agricultural equipment, trucks, trains, and any of the vehicles for land, water, air, and / or snow; other structural members for vehicles such as roof arches, door beams, and the like; structural members for furniture, such as for partition panels, desks, office systems, and the like; and a variety of other structural members that elongate and require bi-directional flexion in at least two places.

More specifically with respect to the roll forming apparatus 30 (FIG 1), an unwinder 50 feeds sheet material 51 from a roll 51 'to a plate 52 (and / or pre-punched die) and in the roller forming device 31. The rollers 53 form the sheet material 51 in a desired cross-sectional shape, such as in a continuous beam 33 that defines a simple tube in the form of D. A welder 54 (optional, used to permanently fix the tube in a closed tubular section) welded the sheet material in the form of a permanent tube. An ascending anchor 55 (optional, used if the internal mandrels are necessary to maintain a shape of a tubular beam during the sweep) supports a downward anchor line to secure internal mandrels in a fixed down position (see Fig. 14-19).

The sweeping station 32 is linked in line to one end of the roller former 31, and includes sweeping rollers to selectively sweep / deform the continuous beam 33 in any of the opposite directions of the longitudinal center line of the continuous beam 33. A cutting device 57 receives the bilateral sweeping beam 33 and cuts this at selected locations relative to the bends formed in the bilateral sweeping beam 33 to rebeam segments 34 having a desired length, and with the sweeping sections contained at strategic locations along the segments of the beam 34. The illustrated bilateral sweep beam segment 34 includes sections 35-40 (FIG 11) all being in a common plane and with sections 36-39 that deform (in FIG. paper and out of paper as illustrated in FIG 1), such that the defense components capable of being in (and continuously supported in) a flat upper table support 58 as they are separated by cutting device 57 with guillotine knife 57 '.

The scanning station 32 (FIG 2) includes a supporting armature 60 with a pair of anchoring struts 61 linked to the pad 62 of the roll former 31, and further it includes a box-like sub-frame 63 for operatively supporting moveable sweeping bending rolls 64 and 65 for double turning and translational movement in support structures 80 and 100 of the structure 60.

The sub-frame 63 includes end plates 66 and transverse up / down plates 67 as well as forward / back transverse plates 67 'assembled to form a box-like configuration with the sweep flexing rolls 64 and 65 positioned therein. Shafts 68 and 69 (see center lines identified in FIG 2) extend through and support the sweep flexure rolls 64 and 65 adjustably. Shafts 68 and 69 each include ends extending through supports 70 and 71 for adjustable support on the transverse plates 67. The pumps / motors 72 and 73 are linked to the upper end of the shafts 68 and 69. The motors 72 and 73 are operatively connected to and independently controlled by a speed controller 74. variable. (See FIG 4.) The covers of the motors 72 and 73 are fixed to the sub-frame 63 by structural housing (not specifically shown, but in the area of numbers 74 and 75).

The sub-frame 63 is operatively supported for double rotational and translational movement by adjustable support structure which engages support structures 80 and 100 in the armature 60 as shown by FIGS. 5, 7, and 10 (and the FIGS. 2-10 generally). More specifically, the sub-frame 63 is supported in an initial position (FIGS 4-5, with the rollers 64 and 65 defining a line perpendicular to the longitudinal direction "A" of the beam 33 as the beam 33 is being formed into a roll. ). As shown in FIGS. 7 and 10, the sub-frame 63 can be selectively rotated (in a downward direction) around the support in sliding members 85 and 86 that support the shaft 68 and shaft 69.

In particular, the adjustable support structure (FIG 2) includes upper and lower support structures 80 and 100 as follows. The upper support structure 80 includes upper and lower support plates 81 and 82 secured together by spacers 83 to define an upper space 84. The adjustable support structure further includes first and second track sliding member guide extensible guides 85 and 86. in the upper part (and additionally two sliding members 85 and 86 in the bottom) which are slidably supported in the space 84 between the plates 81 and 82 in adjacent positions. The guide tracking slide member 85 includes a large end 88 (FIG.5) with a support to both support the sub-frame 63 and allow rotation of the sub-frame 63 along an arcuate downward path. The sub-frame 63 also includes a support which in turn supports the shaft 68. The sliding member 85 also includes a narrow end 90 that adjusts in alignment between and stably engages spacers 83 and 831. In an initial upward position (FIGS 4-5), the angled surfaces between the large and narrow ends 88 and 90 increase stops 83 'for causing exact positioning of the sub-frame 63. The sliding member 86 is similar to the sliding member 85 in its movement, engagement with support supports, and support of the sub-frame 63.

Two of the spacers 831 form a wedge-type stop to limit the upward movement of the plate type guide follower slide member 85. When both plate type guide follower slide members 85 and 86 are in their seated ascending position (FIGS. -5), the sub-frame 63 is in quadrature with the continuous beam 33, with rollers 64 and 65 that are opposed to each other in a configuration perpendicular to the continuous beam 33. When in the sitting position, the sweeping station 32 does not bend the beam 33 continues, so that the beam 33 remains linear.

Two pairs of hydraulic actuators 91 (FIG 4) are connected between the sub-frame 63 and struts 61, with an upper part and a bottom actuator on each side. The actuators 91 on each side are operatively connected to a pump motor 92, which are controlled by the sweeping device controller, which in turn is controlled by a main controller 77 for operating the roll former (FIG 1). (Notably, the controller 77 may be a simple unit, or a host computer that controls several sub-control units around the device 20.) A multi-link chain 94 (also called a "sweep limiter") connects the sub-frame 63 to the struts 61 to limit a maximum angular downward movement of the sub-frame 63 in the main frame 60. The chain 94 provides security to reduce the possibility of the sub-frame 63 moving to an extreme down position that could accentuate and damage machine components , as if one of the actuators 91 fail or break.

As noted above, the adjustable support structure further includes a bottom support structure 100 (FIG 2) which includes identical components and action as the upper support structure 80, which includes upper and lower plate type sliding members, stops / spacers, and actuators.

As shown by FIGS. 4-5, the sweep station 32 has an initial position where the continuous beam 33 does not deviate / deform / sweep. (Notably, the folded portion of the beam 33 illustrated in FIGS 4-5 extending downward from the sweep station was bent / swept before the sub-frame 63 which was moved back to its initial position as in FIGS. -5.) The Sweep station 32 also has a rotated first position (FIGS 6-7) to radically deform beam 33 in a first direction "B" out of a longitudinal center line 95 of beam 33, and a second rotated opposite position (FIGS. 8-10) to radically deform the beam 33 in a second direction "C" opposite the first direction away from the longitudinal center line.

In the first position of FIG. 6, the slide tracking member guide plate 86 is in the initial position, but the slide tracking member guide plate 85 slides down and rotates slightly so that the axis spacing 68 and 69 is maintained (so which continues to engage opposite sides of the continuous beam 33). As a result, the beam 33 is bent in the "B" direction as it passes between rollers 64, 65. In the second position (FIGS 8-10), the plate type guide follower slide member 85 is in the initial position and Sliding member tracking guide plate type plate 86 extends (descending). As a result, the beam 33 is bent in the "C" direction as it passes between rollers 64, 65.

The test has shown that the present sweep station 32 can deform the continuous beam 33 to a sweep of 1000 mm radius in any selected direction when forming material having a tensile strength of 1310 MPa (190 KSI) and a beam tubular cross section of about 70 ram x 70 mm. In addition, the sweep station 32 is controlled variably by the controller 77 such that the sweep bending can be made constant for a particular section of the beam 33, or it can be made to constantly change along a particular section of the beam. beam 33, or can be made in a combination of linear and sweeps. In addition, the sweeps can be made in such a manner that the beam 34 cut from the continuous beam 33 can be symmetrical and can include aligned end sections (see FIG 11, end sections 35 and 40) and offset center section.

As previously discussed, an exemplary vehicle armor 110 (FIG 12) can be made of beams made according to the present inventive principles, and by the present apparatus and method. Armature 110 includes several structural beams / components that have features now possible using the scanning apparatus 30 of the present invention. It is noted that the opposite sides of the vehicle armor 110 will normally be mirror images of one another (or very similar to mirror images) in a current vehicle armor. However, the opposite sides are illustrated as different to illustrate that several possibilities can be accommodated.

In particular, the right half of the vehicle armor 110 shown in FIG. 12 includes a member of single elongated tubular side armor 111 folded with a bi-directional flexure of composite (all the bends are in a vertical plane) at location 112, location 112 which is in a rear wheel of the vehicle when in a vehicle mounted position to provide place for the rear axle of the vehicle. The side armature member 111 further includes a flexure of compound (all the bends are in a horizontal plane) at the location 113 (but the bends that are in an orthogonal direction relative to the first bends). The second bending illustrated at location 113 is slightly lower than the first bending at location 112. It is contemplated that the second bending can be done in a secondary stamping or in a separate bending / reforming operation (see FIG 13) where the tubular beam 34 is supported while being forced into the desired three-dimensional shape. An armature point / support 115 (sometimes called a "crusher tower") was welded to a front of the side armature member 111, such as for mounting a defense reinforcement beam 119 with mounting brackets 119 'welded / fixed thereto. The illustrated support 115 is rectangular in cross section. However, it is contemplated that the support may have a round cross section or other shape. As previously suggested herein, normally a vehicle frame is symmetrically, the difference here is for the purposes of illustration to show alternatives, as will be understood by experts in this field. The illustrated support 115 and reinforcement components are tubular, and may include grinding initiation openings to provide constant and predictable energy absorption during a vehicle impact / impact.

The left half of the vehicle frame 110 (FIG. 12) includes a pair of elongated tubular side frame members 121 and 122 with an overlapped connection 123. The overlapped connection 123 can be by direct overlap of component ends 121 and 122. , or can be made by providing an intermediate tube section formed to extend telescopically at the ends of the components 121 and 122. The components 121 and 122 together are welded, connecting them in a generally aligned fashion to form a lateral reinforcement member no different of member 111. An advantage to using frame members 121 and 122 is that they can be formed into a final form as formed in the roll forming apparatus 30 with the scanning station 32. The supports 115 'can be welded or screwed to ends (rear) of the frame for fixing a rear bumper reinforcement beam 34.

The armature of the vehicle 110 also includes transverse members 125, 126 and 127 that extend between the side armor members 111 and rigidly interconnect the same. The transverse members 125 and 126 are tubular beams (or can be open channels), and include one or more bidirectional bends to meet their dimensional requirements. The end flanges are formed in the transverse members to engage in alignment the respective side reinforcement members and to facilitate welding bonding. Also, if desired, energy management devices and / or grinding initiators can be incorporated in the cross members 125 and / or 126 and / or 127.

FIG. 13 is a flow diagram showing a fabrication of components and welding of an assembly together to form a vehicle frame.

In some circumstances, it may be desired to provide more and more bending sweeps abruptly than the "clash" of the capacity of the previous sweep station 32. In such an event, the auxiliary equipment can be added to the sweep station further increasing its ability to provide a sharply consistent and dimensionally accurate bending sweep. Three basic types of such auxiliary equipment are contemplated, including (1) additional downward external support linked to a downward side of the sweep station 32 (eg, a roller or drive rolls) that engage the continuous beam 33 (called a ""). external stabilizer "), (2) external support ascending (called an ascending bending stabilizer or "bridge support") that engages the beam 33 immediately in front of the rollers 64, 65, and / or (3) an internal stabilizer 142 (illustrated as an "internal mandrel chain") connected to each other in a snake-like manner) (see FIGS 14-18). These concepts may be useful in a sweeping apparatus to produce a bi-directional sweeping beam, or to produce a directionally simple sweeping beam, but it is not believed that it is necessarily required unless the beam 33 is large (eg, greater than 2"x 2") or use high strength materials (eg, greater than 551.5 MPa (KSI)) or use thin-walled materials (eg, less than 2.2 mm thick).

The rising support (called an upward bending stabilizer or "bridge support") (FIG 4) is placed immediately adjacent to the bending rollers to support the beam 33 in its linear form as the rollers 64, 65 come in. the sweeping station 32. The ascending support rests on lateral location 141 and has a lateral shape for aligning slidably engaging beam 33 to support beam 33 as it travels along its central line formed by roller at the pinch point between rollers 64 and 65 of the sweeping station. When making the upright support a solid component (better than a wheel, for example), a front end of the upward support is it can be wedge-shaped, so that the support provided is closer to the pinch point between rollers 64 and 65 as the beam 33 is folded around a roller (e.g., roller 64 or roller 65).

By supporting the beam 33 immediately adjacent to an upward side of the sweep station 32, a dimensional accuracy of the beam 33 can be greatly increased. The reason is because the walls of the beam stabilize and support to prevent unwanted bending and deformation of "opposing bending forces." The opposing bending forces (as used herein) are reactive forces that cause upward deformation in the beam 33 in a direction away from the direction of flexion. These reactive forces are caused by the beam 33 acting as a rise and fall as it is forced to deform around a bending roll (e.g. roll 64). Specifically, the strength of the beam and the resultant stresses in the beam 33 cause an upward portion of the beam 33 (eg, 2.5 to 12.7 cm (1 to 5 inches) ahead of where the beam 33 touches the bending roll 65 ) to bend in a direction away from the flex roll (64).

It is contemplated that the external upward support may be located on only one side of the beam 33, but it is contemplated that the external upward supports will likely be placed on both sides of the beam 33 so that the walls of the beam are supported regardless of whether the direction of the beam 33 is being swept, (that is, the external upward support could stabilize the walls of the beam 33 regardless of whether the beam 33 is being deformed about roll 64 in a first sweep direction, or is being deformed about roll 65 in a second (opposite) sweep direction.) The internal stabilizer 142 (FIGS.14-19) (also called an "internal mandrel-link" or "mandrel snake") includes a plurality of internal mandrel segments connected together by a multi-link chain 151, which at its it is connected to the ascending anchor 55 by a bar 152, such as a solid rod about 2.5 cm (1 inch) in diameter. The segments 160-163 have an outer shape configured to fill an internal cavity of the continuous beam 33 and to slide along the beam 33 as the beam 33 moves through the sweep station. The segments 160-163 have an outer cross-sectional dimension sized so that the walls of the beam 33 do not collapse in the cavity and so that a transverse section of the beam 33 is maintained during the sweep formation process.

The first illustrated ascending segment 160 is elongated (such as 7.6-10.16 cm (3-4 inches)) and includes openings for receiving a bolt 153 connecting the chain 151 (and the block 160) to a curl on the anchor rod 152. The first segment 160 is held in a stationary position located upstream of the pinch point between the rollers 64 and 65. The second segment 161 also elongates (such as about 10.16-15.24 cm (4-6 inches)) which helps in remaining aligned with the line direction of the roll forming process. The second segment 161 is also held in a stationary position located upward of the pinch point between the rollers 64 and 65. The segment 161 is followed by several shorter segments 162 (each about 2.54 or 5.08 cm (one or two inches) long) and a final elongated end segment 163 (elongated to about 5.08-7.62 cm (2-3 inches)). The segments 162 form a stacking line of blocks / mandrels that extend beyond the pinch point between the rollers 64 and 65, and the segment 163 is located downstream of the rollers 64 and 65. A length of the segments 160, 161 and 163 helps maintain its alignment with the continuous beam 33 that is formed. The movement of the segments 162 and 163 follows a shape caused by the rollers 64 and 65 as the rollers 64 and 65 move to different positions (see FIGS 2-10), thus adding stability to the continuous beam 33 as it moves to through the sweep station.

Each segment 161-162 has a through hole, and the segments 160 and 163 have a structure for connection to opposite ends of the links of the chain 151. The chain 151 extends through the segments 161-162 and connects the segments 160-163. Each segment 160-163 is made structurally and interconnected in a shape to allow rotation in any direction from side to side. Specifically, each segment 161-163 has a joint formed by a cylindrically formed nozzle with a narrow upward facing and a cylindrical upwardly engaging hollow, so as to increase to form a rotational support surface that allows rotation of the snake-like internal mandrel. In any direction. It is contemplated that different chains may be used to secure the inner mandrel components together. The illustrated chain 151 includes flat links 155 and transverse bolts 156 interconnecting in a manner similar to a bicycle chain or motorcycle transmission chain for engaging a sprocket. The illustrated links 155 are flat and each has a shape of figure "8" (see FIGS.15 and 17) and may be two or three deep, with ends of the links 155 longitudinally offset and rotated together by bolts so that a Continuous high-strength chain is formed that can be bent in any direction in a horizontal plane ... but not bent in an out-of-plane direction.

FIG. 19 illustrates a modified segment 162A where at least one of the sides of the outer face of the segment 162A includes a roller pin 162B. This makes it possible to reduce the frictional engagement of the sides of the segments 162A since the roller pin 162B rolls along the inner surface of the continuous beam 33 (instead of sliding contact). This configuration is more durable than with the segments 162, but of course the segments 162A are more expensive, and are not potentially practical (or less practical) unless a segment size 162A is sufficiently long and at the same time the pressures of the formation of beam 33 is large enough to justify the use of segment 162A.

A modified roll forming apparatus 30A (FIGS 20-28) is also shown. The components that are similar and / or identical to the apparatuses 30 are identified using the same numbers, but with a letter "A" or "B". This is done to reduce redundant discussion. FIGS. 20-28 are generally similar to FIGS. 2-10, respectively, but with modifications as discussed below.

The apparatus 30A (FIG 20) includes a roller former 31A and scanning station 32A. The scavenging station 32A is anchored by supported armature 200A and operatively supported in a 2OIA base. Notably, the 200A sub-frame and the 2OIA base can be sized to support a weight suitable and size of the 32A sweep station as necessary for particular versions thereof.

At sweep station 32A, plate type expandable slide members 85A and 86A (FIG 20, but see FIG 25) are modified to improve the sweep and reset action. Notably, the slide members 85A and 86A are mirror images of one another, so that only one needs to be described. The sliding member 85A (FIG.25) includes a narrow tail section 90A that includes a tail groove 203A and formed internal surface 204A. The tail groove 203A is formed to engage a roll holder 205A in a post secured to the plate 82A. The sides of the slot 203A are slightly angled, so that the entrance in the slot 203A forms a wide opening in front of the roller support 205A. this allows the slot 203A to capture the roll holder 205A while still allowing some non-linear movement of the slide member 85A during the extension. A lower portion of the slot 203A is rated to participate closely with the roller support 205A, such that the sliding member 85A is positioned exactly when it is in the initial upward position.

A front of the sliding members 85A and 86A are secured together by a tie bar 210A. The loop bar 210A is adjustable in length so that the rollers 64A, 65A are adjusted towards each other to engage the beam 33A, the loop bar 210A can also be adjusted. When the sliding member 85A moves downwardly, the tie bar 210A causes the large end 88A of the sliding member 85A to rotate along an arcuate descending path about the axis 69A during extension. The formed inner surface 204A is formed to accommodate this movement of the sliding member 85A ... allowing the inner surface 204A to prevent interference from the spacer 83A 'and / or 83A.

An adjustment mechanism (FIGS. 29-30) is provided in the sweep station 32A to allow the rollers 64A and 65A to fit (and out of) one toward the other. The screw adjuster 211A and an adjustable supporting bracket 212A to support rollers 64A and 65? are provided. These are operatively supported in the sub-frame 63A for adjusting one position of the bending rollers towards each other (to be pressed against the continuous beam 33A). As noted above, the loop bar 210A is also adjustable to accommodate a similar adjustment in its length.

It should be noted that the "sweep limiter" chain (94) is eliminated in the present sweep station. Instead, a potentiometer or sensing system is linked between a stationary part of the sweep station 32A and the sub-armature 63A. Potentiometers 215A are connected to the controller 77 for controlling actuators 91A ... which in turn controls a position of sub-frame 32A and bending rollers 64A, 65A so that beam 33A is given a particular desired radius of sweep (ie, longitudinal curvature). The potentiometers 215A also operate to sense when (if) the sweep station is "over-extended" in a downward direction. Specifically, a potentiometer 215A, (FIG 21) is linked on each side of the sweep station 32A, with one end 216A which is linked to the plate 81A and its other downward end and 217A linked to the sub-armature 63A. These potentiometers 215A are electrically connected to the controller 77 so that, if a problem occurs, the apparatus immediately stops.

Various modifications are made to various components to handle the high voltages generated in the present scanning station. As well, the modifications are made to increase the efficiency of the operation. For example, the openings 220A in the side end plates 66A and other plates of the sub-frame 63A allow an operator to see in the sweep station, allowing better control since one can see what is happening inside the sweep station. Also, the anchor strut 200A is designed for optional tension handling and to handle a large amount of tension without failure or unacceptable deformation.

It is to be understood that the variations and modifications are they can do in the aforementioned structure without departing from the concepts of the present invention, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language are expressly stated otherwise.

It is noted that in relation to this date, the best method known to the applicant to carry out the aforementioned invention, is that which is clear from the present description of the invention.

Claims (22)

CLAIMS Having described the invention as above, the content of the following claims is claimed as property.

1. An apparatus that forms by roll characterized in that it comprises: a roller former including rollers for forming a sheet of steel material in a structural beam defining a longitudinal line; Y a scanning station in line with the roller former and including a sweeping device selectively for scanning the structural beam in a first direction away from the longitudinal line and in a second direction opposite to the first direction outside the longitudinal line while continuously operating the roll former.

2. The apparatus according to claim 1, characterized in that the rollers form the sheet in a tubular form and the roll former includes a welder to permanently fix the beam in the tubular form.

3. The apparatus according to claim 1, characterized in that the scanning station includes opposite scanning rollers and an adjustable support structure for easily supporting each of the rollers of Opposite sweeps for translational movement.

4. The apparatus according to claim 3, characterized in that the scanning station includes a sub-frame for supporting the opposite scanning rollers, the sub-frame which is operatively supported by the adjustable support structure, and which includes at least one actuator for rotationally moving the subarray in any of the first and second directions.

5. The apparatus according to claim 4, characterized in that the supporting structure is constructed to selectively move at least one of the opposed rollers partially around the other opposed roller in a downward direction.

6. The apparatus according to claim 4, characterized in that the support structure supports the sub-armature for movement in any of the first or second arcuate trajectories extending in a downward direction.

7. The apparatus defined according to claim 6, characterized in that the support structure includes separate actuators connected to each of the slides to move the opposite sweeping rollers between an initial ascending position where the beam is not swept and the different descending positions where the beam is swept in the first direction and then the second address.

8. The apparatus according to claim 6, characterized in that the opposed rollers include first and second axes supported on the sub-frame, and the adjustable support structure includes first and second slide members to selectively operatively support the sub-frame for rotation around the axes. first and second axes.

9. The apparatus according to claim 8, characterized in that the scanning station includes an armature with a pair of upper guides and a pair of bottom guides each define a cavity therebetween, the first and second sliding members each include a portion that extends in one of the cavities to control the movement between the pairs of associated guides.

10. The apparatus according to claim 1, characterized in that the sweeping station includes a main frame, a sub-frame movably supported by the main frame, and includes sliding members that slidably engage the main frame to movably support the frame. subarray on a selected of two different arched trajectories.

11. The apparatus according to claim 10, characterized in that it includes stops that engage the sliding members to define exactly one Initial ascending position where the structural beam remains linear and a longitudinally curved shape does not occur.

12. The apparatus according to claim 3, characterized in that it includes a support in an upward direction placed immediately upward and adjacent to the sweeping rollers.

13. The apparatus according to claim 1, characterized in that it includes at least one internal mandrel placed in part between the opposite rollers in the scanning station.

14. The apparatus according to claim 13, characterized in that at least one internal mandrel includes a plurality of internal interconnected segments to form a stackable flexible chain with a given plane but in opposite directions in the plane.

15. A scanning station for scanning sections of a beam outside a longitudinal line defined by the beam, characterized in that it comprises: a main armor; a sweeping forming device including a sub frame operatively supported on the main frame for first position movement to sweep a first section of the beam in a first direction away from the longitudinal line and for movement to a second position for Sweep a second section of the beam in a second direction away from the longitudinal line, the second direction being on the opposite side of the first direction.

16. The scanning station according to claim 15, characterized in that it includes at least one internal mandrel placed partly between the opposed rollers in the device that forms the sweep.

17. The scanning station according to claim 16, characterized in that at least one internal mandrel includes a plurality of internal interconnected segments to form a stackable flexible chain within a given plane but in opposite directions in the plane.

18. A roll forming method characterized in that it comprises steps of: roll formation a sheet of material on a continuous beam defining a longitudinal line; Y during the roll forming step, sweeping a first section of the continuous beam in a first direction away from the longitudinal line and then sweeping a second section of the continuous beam away from the longitudinal line in a second direction different from the first direction.

19. The method according to claim 18, characterized in that the different direction is opposite to the first direction.

20. The method according to claim 19, characterized in that it includes providing an actuator adapted to rotate in any of the opposite directions from the longitudinal line and includes controlling the actuator to the position of the first and second sections at the desired locations along the continuous beam.

21. The method according to claim 20, characterized in that it includes reforming the beam in a third direction different from the first and second directions.

22. A beam component characterized in that it comprises: a beam formed by a roller having a constant cross section and formed of a sheet of material with a Resistance of at least 414 MPA (60 KSI); the beam as formed in roll is initially substantially linear and defines a longitudinal center line, but includes at least first and second sections where the first section is bent in a first direction away from the center line and the second section is bent in a second direction direction away from the center line but in a direction opposite to the first section.